Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B29/00—Layered products comprising a layer of paper or cardboard
  • B32B29/002—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material
  • B32B29/005—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to another layer of paper or cardboard layer
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/04—Layered products comprising a layer of synthetic resin as impregnant, bonding, or embedding substance
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
  • B32B27/10—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/28—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/42—Layered products comprising a layer of synthetic resin comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B29/00—Layered products comprising a layer of paper or cardboard
  • B32B29/06—Layered products comprising a layer of paper or cardboard specially treated, e.g. surfaced, parchmentised
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G8/00—Condensation polymers of aldehydes or ketones with phenols only
  • C08G8/04—Condensation polymers of aldehydes or ketones with phenols only of aldehydes
  • C08G8/08—Condensation polymers of aldehydes or ketones with phenols only of aldehydes of formaldehyde, e.g. of formaldehyde formed in situ
  • C08G8/10—Condensation polymers of aldehydes or ketones with phenols only of aldehydes of formaldehyde, e.g. of formaldehyde formed in situ with phenol
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
  • D21H17/20—Macromolecular organic compounds
  • D21H17/33—Synthetic macromolecular compounds
  • D21H17/46—Synthetic macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
  • D21H17/47—Condensation polymers of aldehydes or ketones
  • D21H17/48—Condensation polymers of aldehydes or ketones with phenols
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
  • B32B2260/02—Composition of the impregnated, bonded or embedded layer
  • B32B2260/028—Paper layer
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
  • B32B2260/04—Impregnation, embedding, or binder material
  • B32B2260/046—Synthetic resin

Definitions

• the invention relates to a process for the preparation of a phenol-formaldehyde resin, by causing phenol and formaldehyde to condense under the influence of a basic catalyst.
• Suitable basic catalysts are for example sodium hydroxide, barium hydroxide and calcium hydroxide and organic amines.
• Phenol-formaldehyde resins are pre-eminently suitable for impregnating for example paper.
• Paper is impregnated with a phenol-formaldehyde resin, dried and stacked.
• the stack obtained in this manner is cured under pressure, as a result of which a laminate is obtained.
• the laminate bends easily at temperatures of between 140° and 200° C.
• the deformability of laminates for this application is called the postforming behaviour.
• the laminates are used for for example electrical, insulation and decorative applications.
• the aim of this invention is to prepare a phenol-formaldehyde resin with which laminates can be produced that show better postforming behaviour than is possible according to the present state of the art.
• the catalyst is an aqueous solution that contains alkali metal ions, carbonate ions, anions of carboxylic acids and one or more ions selected from among transition metal ions and borates.
• the catalyst consists of an aqueous solution that contains alkali metal ions, carbonate ions, anions of carboxylic acids and transition metal ions and/or borates.
• the transition metal ion is an ion of cobalt and/or chromium. In general it is borate, metaborate and/or tetraborate.
• the aqueous solution usually has a pH that lies between 8.5 and 14.
• the pH lies between 10 and 14 and in particular between 11 and 12. It is important that the pH is higher than 8.5 because otherwise the carbonate decomposes to carbon dioxide and other substances.
• the anions of carboxylic acids generally have between 1 and 12 carbon atoms.
• the carboxylic acids may optionally be hydroxylated mono- and dicarboxylic acids. These anions of carboxylic acids will generally be present in the aqueous solution as a dissolved alkali-metal salt of the carboxylic acid.
• carboxylic acids examples include formic acid, acetic acid, oxalic acid, propionic acid, malonic acid, butyric acid, succinic acid, valeric acid, glutaric acid, hexanoic acid, adipic acid, 2-hydroxyhexanoic acid, heptanoic acid, octanoic acid, nonanoic acid, dodecanoic acid, pimelic acid, suberic acid and azelaic acid.
• the concentration of anions of carboxylic acids in the aqueous solution expressed in the concentration of organically bound carbon is between 3 and 40 wt. %, preferably between 10 and 30 wt. %.
• Possible alkali metal ions are sodium and potassium ions.
• the concentration of alkali metal ions in the aqueous solution is generally between 3 and 13 wt. %, preferably between 4 and 9 wt. %.
• the concentration of carbonate ions in the aqueous solution is generally between 2 and 20 wt. % and preferably between 3 and 8 wt. %.
• the amount of transition metal ions or borate in the aqueous solution is generally between 3 and 100 ppm and preferably between 4 and 50 ppm.
• a solution that is formed in a process as described in U.S. Pat. No. 3,946,077 can very advantageously be chosen as the catalyst described above.
• U.S. Pat. No. 3,946,077 describes how in an alkane oxidation process an organic process stream is treated with an alkali solution to saponify the esters present and to separate the carboxylic acids released through the saponification or otherwise.
• the solution that is formed in this process, the saponification lye, hereinafter referred to as aliali solution has a composition that now appears to be applicable as a catalyst.
• the main portion of the transition metal ion or boron in the form of boric acid that is used as the catalyst in the alkane oxidation process also ends up in this aqueous alkali solution.
• the alkali solution is usually regarded as a worthless stream, from which the organic substances present as well as the transition metal or boron have to be removed on account of environmental requirements. In particular this applies to the alkali solution that is formed in a cyclohexane oxidation process. Many attempts have already been made to process this alkali solution in a satisfying manner.
• GB-A-1398293 proposes to burn the alkali solution. Objections to this process are that the alkali melt residue thus obtained has a great digesting power with respect to all materials used for brickwork in the combustion oven. Another drawback is that the transition metal or boron is entrained with the combustion off-gas, which entails an unacceptable burden on the environment.
• a drawback of this process is that extra process steps and energy are necessary to carry out this process.
• An additional drawback is that this process does not remove the transition metal or boron present in the alkali solution.
• this alkali solution as a catalyst in the preparation of phenol-formaldehyde resins according to a process according to the invention, the aforementioned drawbacks are avoided and at the same time a destination is found for the alkali solution that is formed in an alkane oxidation process.
• this applies to a cycloalkane oxidation process in which the cycloalkane consists of between 5 and 12 carbon atoms.
• it applies to a cyclohexane oxidation process.
• Phenol-formaldehyde resins can be used in for example rock wool, chipboard, paints, filters and rubbers.
• Example 1 was repeated with the difference that now an NaOH solution was used as the catalyst.
• the base concentration was 2.2 wt. %, relative to the NaOH.
• the viscosity of the resin solution thus obtained was found to be 40 mPas.
• Kraft paper of 250 g/m 2 was impregnated with the phenol-formaldehyde resin obtained in Example I.
• the impregnated paper was then dried in a ventilation oven at 120° C.
• the resin content of the paper was 45 wt. % (including moisture).
• the resin-impregnated paper was then compressed to a 1-mm thick high-pressure laminate consisting of three layers of paper. The compression was effected at a temperature of 140° C. and a pressure of 8 MPa. At this pressure the stack of impregnated paper was heated for 15 minutes, maintained at compression temperature for 15 minutes and cooled for 10 minutes.
• the laminate thus obtained was tested for impact resistance and moisture sensitivity according to ISO 4586 and for postforming behaviour.
• the postforming test was derived from ISO standard 4586.

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• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Health & Medical Sciences (AREA)
• Medicinal Chemistry (AREA)
• Polymers & Plastics (AREA)
• Organic Chemistry (AREA)
• Phenolic Resins Or Amino Resins (AREA)
• Laminated Bodies (AREA)
• Catalysts (AREA)

Applications Claiming Priority (2)

Publications (1)

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ID=19861182

Family Applications (1)

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Cited By (3)

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Citations (5)

• 1992
  • 1992-08-17 NL NL9201461A patent/NL9201461A/nl active Search and Examination
• 1993
  • 1993-08-16 CN CN93117855A patent/CN1040220C/zh not_active Expired - Fee Related
  • 1993-08-16 KR KR1019930015995A patent/KR940003980A/ko not_active Application Discontinuation
  • 1993-08-17 US US08/107,199 patent/US5359024A/en not_active Expired - Fee Related

Patent Citations (5)

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